Method of manufacturing solid surface counter top

ABSTRACT

A solid surface counter top is manufactured by preparing a solid surface raw-material sheet having a glossy surface to which a protection film is attached, processing a groove on an opposite surface of the glossy surface, leaving a connection portion having a fine thickness, to fold the raw-material sheet to fit to a shape of the top plate having at least one bent portion, heating the connection portion, and folding the row-material sheet to fit to the shape of the top plate by bending the heated connection portion.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a method of manufacturing solid surface counter top, and more particularly, to a method of manufacturing solid surface counter top making the manufacturing process remarkably fast, and reducing labor dramatically.

2. Description of the Related Art

In general, solid surfacing is manufactured for interior applications where a decorative, durable, wear and stain resistant surface is required. Horizontal applications include vanity tops, countertops, residential and commercial furniture, window sills and thresholds. Vertical applications include wall panels, wainscoting, backsplashes, baseboards, and bath and shower enclosures.

For example, as shown in FIG. 1, a sink consists of a cabinet 15 for storing items, a solid surface counter top 10 installed on the top of the cabinet 15 to carry out cooking thereon, and a basin 30 inserted in an opening formed in part of the top plate 10.

The finished solid surface top 10 is divided into three parts: a flat panel portion 11, edge portion 12 and backsplash portion 13, respectively. A conventional method, as shown in FIGS. 2A through 2D, has been used to manufacture the solid surface counter top. Generally, a row-material sheet 1 having one surface that is polished is used as the solid surface counter top. The row-material sheet 1 having a protection film 1 a for preventing scratches attached to the glossy surface is supplied to a manufacturing line. Then, the protection film 1 a is ripped off from the raw-material sheet 1 and the raw-material sheet 1 is cut into three parts of the flat panel portion 11, the edge portion 12, and the backsplash portion 13, as shown in FIG. 2B. The cut three parts are attached together by using an adhesive, fitting to the shape of the solid surface counter top plate 10, and clamped until the adhesive is hardened as shown in FIG. 2C. Reference numeral 14 indicates an auxiliary member that is attached to make a portion where the flat panel 11 and the backsplash 13 meet, smoothly curved. When the adhesive is completely hardened, edge portions exposed to a user are made smooth as shown in FIG. 2D, through a process such as round cutting and sanding. Lastly, the glossy surface that is damaged during the attachment and processing steps is polished again to give luster.

However, the above method requires quite a number of steps such as detaching the protection film in advance, cutting, attaching, round cutting, and sanding and polishing, manufacturing there for is inconvenient and it takes a long time to complete a product.

Unlike the above general attachment method, the top plate 10 can be manufactured in a V-grooving method as shown in FIGS. 3A through 3E. Referring to FIG. 3A, a protection film 1 a attached to a glossy surface of the solid surface raw-material sheet 1 is ripped off. An adhesive tape 1 b is attached to a surface opposite to a portion to be V-grooving process, so that the respective portion are not completely separated as shown in FIG. 3B. Next, as shown in FIG. 3C, the V-grooving process is performed with respect to a boundary portion between the flat panel portion 11 and each of the edge 12 and backsplash 13. After the V-grooving process, the processed surfaces are coated with an adhesive and bent to have the shape of the top plate 10 and the adhesive is hardened, as shown in FIG. 3D. When the adhesive is completely hardened, the adhesive tape 1 b is detached and edge portions exposed to a user and portions where the adhesive squeezes out are processed in a method such as round cutting and sanding, so that a product is manufactured as shown in FIG. 3E. Lastly, the glossy surface that is damaged during the attachment and processing steps is polished again to give luster.

However, in the above method, since quite a number of steps from the step of detaching the protection film 1 a from the raw-material sheet 1 in advance, to the final polishing step are required, manufacturing is inconvenient and productivity is lowered. Thus, an improved method of manufacturing solid surface counter top is needed.

SUMMARY OF THE INVENTION

To solve the above and/or other problems, the present invention provides a method of manufacturing a solid surface counter top having a simplified manufacturing process so that rapid product manufacturing is possible.

According to an aspect of the present invention, a method of manufacturing a solid surface counter top comprising preparing a solid surface raw-material sheet having a glossy surface to which a protection film is attached, processing a groove on an opposite surface of the glossy surface, leaving a connection portion having a fine thickness, to fold the raw-material sheet to fit to a shape of the top plate having at least one bent portion, heating the connection portion, and folding the raw-material sheet to fit to the shape of the top plate by bending the heated connection portion.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other features and advantages of the present invention will become more apparent by describing in detail preferred embodiments thereof with reference to the attached drawings in which:

FIG. 1 is a perspective view illustrating the structure of a typical sink adopting a solid surface counter top;

FIGS. 2A through 2D are views illustrating the process of manufacturing a solid surface counter top in a conventional attachment method;

FIGS. 3A through 3E are views illustrating the process of manufacturing a solid surface counter top in a conventional V-grooving method;

FIGS. 4A through 4E are views illustrating the process of manufacturing a solid surface counter top according to a first preferred embodiment of the present invention;

FIG. 5 is a view illustrating a modification of the shape of a edge portion in manufacturing the solid surface counter top shown in FIG. 4E;

FIGS. 6A through 6E are views illustrating the process of manufacturing a solid surface counter top according to a second preferred embodiment of the present invention; and

FIGS. 7A through 9E are views illustrating modifications of the shape of a edge portion in manufacturing the solid surface counter top according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIGS. 4A through 4E, in a method of manufacturing a solid surface counter top according to a first preferred embodiment of the present invention, first, an raw-material sheet 100 is prepared for manufacturing a solid surface counter top. A protection film 100 a for preventing a glossy surface from scratches is attached to the raw-material sheet 100, as shown in FIG. 4A. In the present invention, the raw-material sheet 100 is processed without detaching the protection film 100 a.

The processing is performed at a surface opposite to the glossy surface where the protection film 100 a is attached. As shown in FIG. 4B, a groove 130 a having a “T” shape is formed between the flat panel portion 110 and the backsplash 130 while a groove 120 a having an angled “T” shape is formed between the flat panel portion 110 and the edge 120. Connection portions 120 b and 130 b having a fine thickness are left on the grooves 120 a and 130 a, respectively, so that the respective portions are not completely separated. The thickness of the connection portions 120 b and 130 b is preferably about 1.5-2.0 mm.

When the processing of the grooves 120 a and 130 a is completed, as shown in FIG. 4C, the connection portions 120 b and 130 b are heated by a heating/cooling apparatus 20 so that plastic deformation is possible. The heating/cooling apparatus 20 includes a heating portion 21 and a cooling portion 22. While the heating portion 21 of the heating/cooling apparatus 20 heats the connection portions 120 b and 130 b, the cooling portion 22 cools a portion near the connection portions 120 b and 130 b the so that the heat is not transmitted to the nearby portion. A typical heater and a container storing water may be used as the heating portion 21 and the cooling portion 22, respectively.

The raw-material sheet 100 is folded to fit to the shape of the solid surface counter top, as shown in FIG. 4D, by bending the heated connection portions 120 b and 130 b. Then, the sufficiently heated connection portions 120 b and 130 b are smoothly bent so as to be folded to fit to the shape of the solid surface counter top. Preferably, spaces formed as the grooves 120 a and 130 a are folded are filled with an adhesive so as to firmly fix the shape.

Then, the protection film 100 a adhering to the glossy surface is detached so that the solid surface counter top as shown in FIG. 4E is obtained. That is, since smooth curves are formed as the connection portions 120 b and 130 b are bent at the boundary portions between the flat panel portion 110 and each of the edge 120 and backsplash 130, the additional round cutting and sanding steps are not needed. Accordingly, since the polishing step to give luster is not needed as well, the entire manufacturing process is completed by simply detaching the protection film 100 a. In this regard, the protection film detaching step is preferably performed after the completed top plate is delivered to a customer because detaching the protection film 100 a, on which a trademark of the raw-material sheet 100 is marked, in front of the customer, may give reliability of the product to the customer. Reference numeral 140 indicates a reinforcement member which is attached to the rear side of the backsplash 130 to balance against the edge 130. A typical rectangular shaped plate is used as the reinforcement member 140.

Thus, compared to the conventional method in which the additional steps such as detaching the protection film in advance, round cutting, sanding, and polishing are needed, the manufacturing method according to the present invention is simplified by far so that rapid manufacturing is possible.

In addition to the “L” shape described above, the edge 120 may have a “

” shape as shown in FIG. 5. In this case, two grooves 120 a and 120 a′ having the angle “T” shape are formed and bent by heating connection portions 120 b and 120 b′, so that the “

” shape can be formed as shown in the drawing. Also, space formed as the grooves 120 a, 120 a′, and 130 a are folded are filled with an adhesive so as to firmly fix the shape.

Next, FIGS. 6A through 6E show a method of manufacturing a solid surface counter top according to a second preferred embodiment of the present invention. Referring to FIG. 6A, a raw-material sheet 200 on which a protection film 200 a for protecting a glossy surface is prepared as a material. A surface opposite to the glossy surface where the protection film 200 a adheres is processed. As shown in FIG. 6B, a rectangular groove 230 a is formed between a flat panel portion 210 and a backsplash 230 and a “Y” shaped groove 220 a open at an angle of 90° is formed between the flat panel portion 210 and a edge 220. In the present preferred embodiment, unlike the first preferred embodiment, the edge 220 is shaped as “

” Thus, two “Y” shaped grooves 220 a are formed. If the “L” shape is needed, it is necessary to form a single “Y” shaped groove 220 a.

Connection portions 220 b and 230 b having a thickness of about 1.5-2 mm are left on the grooves 220 a and 230 a so that the respective portions are not completely separated.

After the grooves 220 a and 230 a are completely processed, as shown in FIG. 6C, the connection portions 220 b and 230 b are heated by the heating/cooling apparatus 20 (refer to FIG. 4C) so that plastic deformation is possible. While the heating portion 21 of the heating/cooling apparatus 20 heats the connection portions 220 b and 230 b, the cooling portion 22 cools a portion near the connection portions 220 b and 230 b so that the heat is not transmitted to the nearby portion.

The raw-material sheet 200 is folded to fit to the solid surface counter top, as shown in FIG. 6D, by bending the heated connection portions 220 b and 230 b.

Then, the sufficiently heated connection portions 220 b and 230 b are smoothly bent so as to be folded to fit to the shape of the solid surface counter top. Preferably, spaces formed as the grooves 220 a and 230 a are folded are filled with an adhesive so as to firmly fix the shape.

Then, the protection film 200 a adhering to the glossy surface is detached so that the solid surface counter top as shown in FIG. 6E is obtained. As described above, to give reliability of the product to the customer, the protection film detaching step is preferably performed after the completed top plate is delivered to the customer.

In the present preferred embodiment, since the shapes of the grooves 220 a and 230 a are simpler than those of the first preferred embodiment, processing the grooves 220 a and 230 a is easier than the first preferred embodiment. In contrast, in the present preferred embodiment, since a reinforcement member 240 to be installed at the rear of the backsplash 230 needs to be processed to fit to curvature of the connection portion 230 b which is curved, as shown in FIG. 6E, the preparation of the reinforcement member 240 may be relatively difficult. Thus, considering the convenience in processing and stability in bending, appropriate groove shapes are selected among the above-described grooves and then combined.

In some cases, a unique shape different from the above-described shapes, for example, the “L” shape or “

” shape, is requested for the edge of the solid surface counter top. For example, FIG. 7B shows an edge 320 having a round shape. In this case, a groove 320 a in which a circular rod type molding member J is inserted and rolled is processed. Then, the above-described heating and bending steps are performed by inserting the molding member J in the groove 320 a. Thus, the inner surface of the edge 320 is formed circular along the outer circumferential shape of the molding member J. Preferably, an adhesive is coated between the groove 320 a and the molding member J.

Also, as shown in FIGS. 8A through 8D, in order to make the inner space of the edge 420 have a bowl shape, a molding member J corresponding to the shape is inserted in the inner space and the edge 420 is bent. That is, a portion in which the molding member J is to be inserted is heated by using the heating portion 21 of the heating/cooling apparatus 20, as shown in FIG. 8A. Then, the end portion of the edge 420 is lifted, as shown in FIG. 8B, and the molding member J is inserted, as shown in FIG. 8C. In this state, by bending an end portion of the edge 420, the shape as shown in FIG. 8D is obtained. Reference numeral 420′ indicates a protruding portion to prevent water drops or pencils falling from the edge 420. The protruding portion 420′ can be made in a method shown in FIGS. 9A through 9E. That is, as shown in FIG. 9A, a rectangular groove 621 and an angled “T” shaped groove 622 are formed in the edge 620. The angled “T” shaped groove 120 a in the previous preferred embodiment is open at an angle of 90° to make a right angle when folded. However, in the present preferred embodiment, the angled “T” shaped groove 622 is formed to have an angle of about 100°. After the heating step of FIG. 9B, the angle “T” shaped groove 120 a is bent to be less than 90°, as shown in FIG. 9C. Then, as shown in FIG. 9D, the rectangular groove 621 is bent to form a protruding portion 620′. In the state, as shown in FIG. 9E, the grooves 621 and 622 are filled with an adhesive B which is hardened and functions as a caulking member to firmly fix the shape.

Thus, in the manufacturing method according to the present invention, as shown in the first and second preferred embodiments, grooves are formed, leaving the connection portions, on the opposite surface of the glossy surface where the protection film adheres and the connection portions are heated and bent. Consequently, the steps of detaching the protection film in advance, round cutting, sanding, and polishing can be omitted. The grooves processed in the flat panel portion and the edge and backsplash are formed by combining the above-described shapes. The solid surface counter top plate manufactured as above can be used as top plates for kitchen sinks, bathroom washbasins, tables, counter desks, window sills, bathroom door sills, reception desks, and furniture.

As described above, the method of manufacturing the solid surface counter top plate according to the present invention has the following effects.

First, since the steps of detaching the protection film in advance, round cutting, sanding, and polishing, which are required in the conventional method, are not needed, the manufacturing process is simplified so that products can be rapidly manufactured.

Second, since the process is simplified, the product cost is reduced and price competitiveness is improved.

Third, since the steps such as round cutting, sanding, and polishing generating dusts are not needed, the working environment is improved.

Fourth, since the protection film on which the trademark of the raw-material sheet is marked is detached after the product is delivered to the customer, it is possible to give reliability of the product to the customers. 

1. A method of manufacturing a solid surface counter top comprising: preparing a solid surface raw-material sheet having a glossy surface to which a protection film is attached; processing a groove on an opposite surface of the glossy surface, leaving a connection portion having a fine thickness, to fold the raw-material sheet to fit to a shape of the top plate having at least one bent portion; heating the connection portion; and folding the raw-material sheet to fit to the shape of the top plate by bending the heated connection portion.
 2. The method as claimed in claim 1, further comprising cooling a portion near the heated portion to prevent heat from being transmitted to the backsplash when the connection portion is heated.
 3. The method as claimed in claim 1, wherein, when the connection portion is bent, a molding member having a predetermined shape is inserted in an inner space of the connection portion to be bent to maintain the shape of the molding member.
 4. The method as claimed in claim 1, wherein the top plate has a flat panel portion and edge and backsplash disposed at both sides of the flat panel portion and each of boundary portions is bent.
 5. The method as claimed in claim 1, wherein the protection film is detached after the solid surface counter top is delivered to a customer.
 6. The method as claimed in claim 1, wherein a trademark of the raw-material sheet is marked on the protection film. 